Audi Workshop Service and Repair Manuals

Installing gearbox - vehicles with 8-cyl. MPI engine (Audi S4) Installation is carried out in reverse sequence; note the following:   Note t  Renew self-locking nuts. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  Re-attach heat shield sleeves at the same locations when re-installing. t  Re-attach all cable ties at the same locations when re-installing. –  Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines -G 000 100- to the splines. Do not grease guide sleeve. l  It should be possible to push the clutch plate back and forth slightly on the input shaft. –  Check clutch release bearing for wear and make sure the plastic ring is securely attached; renew if necessary → Chapter. –  Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. –  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary. –  Place intermediate plate on dowel sleeves at engine flange. –  Before installing gearbox, tie electrical wiring off to one side so that it cannot be trapped between the engine and the gearbox. –  Place gearbox on gearbox jack.

–  Lightly lubricate surface where plunger and clutch release lever make contact -arrow B- using copper grease -Z 381 351 TE-. –  Raise gearbox far enough to be able to install clutch slave cylinder with bracket for hose/pipe assembly. –  Guide slave cylinder -1- into opening in gearbox housing, keeping it as straight as possible (without tilting plunger -arrow A-) and insert in recess -arrow B- on clutch release lever -3-. –  Use new hexagon socket head bolt -2- to secure to gearbox.   Note If the slave cylinder -1- is inserted at an angle, there is a danger that the plunger -arrow A- will be guided past the clutch release lever -3-.

–  Tighten bolt -arrow- to specified torque.   Caution After installing the slave cylinder carefully press the clutch pedal. If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. The plunger of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.

–  Insert gearbox, making sure there is sufficient clearance to drive shafts. –  Install starter -arrows- and tighten top left and right engine/gearbox connecting bolts.   Note The bottom bolts are fitted at a later stage.

–  Bolt bracket for front exhaust pipe (left-side) to gearbox -arrows-.

–  Fit gearbox selector lever -2- and tighten nut -1-. Tightening torque → Item

–  Attach connector -arrow- for reversing light switch -F4- on right side of gearbox.

–  It is important to clean the threaded holes for the propshaft bolts to remove any remaining locking fluid. The threads can be cleaned with a thread tap. –  Bolt propshaft onto gearbox -arrows- → Rear final drive 01R; Rep. Gr.39 or → Rear final drive 0AR; Rep. Gr.39 or → Rear final drive 0AR; Rep. Gr.39.

–  Bolt on heat shield for propshaft -arrows-.

–  Bolt tunnel cross member onto gearbox mounting -arrows-. Tightening torque → Item –  Install front exhaust pipes with starter catalytic converter and main catalytic converter → Engine, mechanics; Rep. Gr.26.

–  Attach Lambda probe wiring to gearbox at the points marked with -arrows-.   Note In the illustration the engine/gearbox assembly has been removed.

–  Bolt push rod -1- onto gearbox. Tightening torque → Item –  Secure connecting rod -2-. Tightening torque → Item

–  Bolt drive shafts to flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install heat shields -arrow- for drive shafts (left and right).

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to rear cross member from below (place a block of wood -arrow- between lifting column and cross member). –  Push rear cross member upwards with engine and gearbox jack -V.A.G 1383 A-. –  Renew bolts -3 … 4-. –  Bolt on tunnel cross member hand-tight.

–  Install clamps -arrows- for exhaust system. –  Install exhaust system and perform stress-free alignment → Rep. Gr.26.

–  First remove front bolts -2- and -3- on subframe (left and right). Then remove bolts -1-. –  Lower subframe at the front.

–  Tighten three bottom engine/gearbox securing bolts -arrows-.

–  Renew bolts for subframe. Wheel alignment must be performed if it was not possible to fully insert both locating pins -3393- into holes in subframe before subframe was detached. –  Tighten new bolts for subframe, consoles for engine mountings and tunnel cross member only to initial torque setting, do not yet turn further (wait until wheel alignment has been carried out). 1 -  65 Nm 2 -  110 Nm 3 -  110 Nm 4 -  75 Nm   WARNING The vehicle must not be driven in this condition. –  Perform wheel alignment after completing all assembly work → Rep. Gr.44.

Wheel alignment does not have to be performed if it was possible to fully insert both locating pins -3393- into holes -1- and -2- in subframe before subframe was detached. –  Locate subframe on body before tightening bolts using locating pins -3393-. l  Holes -1- and -2- in subframe and hole -3- in console for engine mounting must be exactly aligned on both sides. –  Secure subframe → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Secure tunnel cross member → Chapter.

All models: –  Tighten nuts -1- for engine mountings. The remaining installation steps are carried out in the reverse sequence; note the following points: –  Check selector mechanism setting and adjust if necessary → Chapter. –  Check gear oil level in gearbox → Chapter. –  Follow steps required after connecting battery → Electrical system; Rep. Gr.27.   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques ±15%.

Engine/gearbox securing bolts

Item	Bolt	Nm
1, 2	M12x120	65
3	M12x110	65
4, 5	M12x105	65
6	M12x130	65
7	M12x170	65
8, 9, 10	M10x60	45
A	Dowel sleeves for centralising

Tightening torques

Component	Nm
Clutch slave cylinder to gearbox	23 1)
Bracket for exhaust pipe lug.	23
Heat shields above drive shafts to gearbox	23
Heat shield for propshaft to gearbox cover	25
Engine mounting to engine support	23
Bracket for noise insulation to subframe	10
l  1) Renew bolt.